What Is the Brake Rotor Replacement Process?

For best results, replace your brake pads and rotors simultaneously. It streamlines maintenance, boosts performance, and helps your braking system last longer.

However, even minor errors during the replacement can compromise your braking power or even damage components, like the brake line. That’s why you should leave the replacement to an experienced auto repair professional. 

Here’s how they’ll replace rotors and pads:

1. Park on a flat, dry surface, engage the emergency brake or parking brake, and secure the vehicle with wheel chocks.
2. Check the brake fluid level. If it’s already full, they’ll remove a small amount to prevent overflow when the caliper piston is compressed.
3. Jack up the car, place it securely on jack stands, remove the lug nuts, and take off the wheel. They’ll be mindful not to strain the brake hose when moving the caliper aside.
4. Remove the brake caliper bolts and caliper (the steps to remove the brake caliper may vary depending on your vehicle).
5. Take off the old brake pads and slide off the worn rotor.
6. Inspect and clean the rotor mounting surface to ensure the new rotor sits evenly, preventing pedal pulsation.
7. Clean and install the new rotor. Once done, replace the brake hardware, like clips and shims, with new ones.
8. Install the new brake pads. Note the wear sensor position orientation to install the new brake pads correctly. 
9. Reinstall the caliper and tighten the bolts using a torque wrench to the manufacturer’s specifications.
10. Recheck the brake fluid reservoir, pump the brake pedal until it becomes firm, then top up the fluid if needed.
11. Reinstall the wheel, tighten the lug nuts, and lower the car to the ground. Repeat the process for each wheel.
12. Before driving, ensure the brake pedal feels firm and take a gentle test drive to bed in the new pads and rotors.

How Much Does It Cost To Replace Brake Rotors?

You may need to pay between $560 and $730 for a brake rotor replacement. 

The total cost depends on the vehicle, local labor charges, as well as the type of rotor and pad used. 

When Should You Replace Brake Rotors?

Here are some common signs that indicate you need a new rotor:

1. Vibration and pulsation: Stepping on the brakes shouldn’t cause vibration — unless the ABS is activating. If you feel pedal pulsation or your steering wheel shakes while braking, it often means the pads are hitting a worn or uneven rotor that likely needs replacement.
2. Rotor wear over time: With time, brake rotors wear out just like many other vehicle parts. And eventually, you’ll need to resurface or replace them with new ones, especially when the brake part shows visible wear.
3. Brake noise: A chattering or intermittent squeaking brake noise often points to a warped or uneven rotor. Sometimes contaminants or light debris on the surface can worsen these noises — which is why new rotors are always cleaned with brake cleaner during brake replacement. 
4. Blue color: A blue tint or spots on your brake rotors usually indicate excessive heat. Blue spots on the rotor surface shouldn’t be machined, as the metal’s hardness and elasticity are long gone. In this case, you should get a brake repair and replacement.
5. Rotor thickness: Brake rotors have a minimum thickness requirement. If you’ve already machined your rotors, they’re likely too thin for reuse and should be replaced.
6. Brake overheating: This can happen during long downhill braking, causing brake rotor deformation and brake fade. While resurfacing may help temporarily, uneven material removal can lead to re-warping — making brake rotor replacement the only long-term fix.
7. Rotor surface condition: Machining is impossible if your rotor surface has deep ridges and corrosion. You’ll either harm the brake lathe or cut the rotor too thin to be safely reused.

PRO TIP: Ask if your auto repair shop offers a free brake inspection to stay ahead of potential brake system issues.

Can You Drive With Bad Rotors?

No, driving with bad rotors isn’t safe. 

Damaged or warped rotors affect your brake performance, making your braking feel uneven and unpredictable. If you continue driving on them, the brake problem will only worsen, and your brake pads will wear out even faster.

3 Brake Rotors Replacement FAQs

Here are the answers to some common brake rotor replacement questions:

1. What Causes Brake Rotors To Warp?

Here are some common causes of disc brake rotor warping:

• Brake rotors can warp when overheated brake pads leave glazing or residue on the rotor surface. Cleaning new rotors with brake cleaner during installation can help prevent contaminants from contributing to this buildup.  

• Your rotor’s surface can wear down over time due to use and may require resurfacing during brake service. Excessive heat can raise metal areas higher. This occurs when you consistently apply pressure to your brakes, leading to a warped rotor.

2. How Long Do Brake Rotors Last?

On average, conventional steel brake rotors last 30,000 to 70,000 miles. However, rotor wear depends on several factors, including your driving style, vehicle, and the frequency of brake service.

A carbon-ceramic brake disc can last a lifetime. However, even this rotor’s durable design can be impacted by driving style and conditions.

3. What Are The Different Types Of Brake Rotors?

Here are the different brake rotor types:

• Blank and smooth Rotors: These are simple and affordable rotors found in the disc brakes of most passenger vehicles, like standard sedans.

• Slotted rotors: These rotors have special slots arranged around the exterior rotor surface. They’re found in heavy-duty trucks and SUVs, where consistent brake maintenance is crucial due to higher braking loads.

• Vented rotors: These rotors have cooling vents located between the two surfaces. Several modern cars feature vented rotors on the front, ideal for a daily commute or towing smaller loads.

• Drilled rotors: These rotors have holes drilled in a spiraling design across their surface, rather than slots. Cars in wet climates have drilled rotors to enhance brake performance in damp and cold weather conditions.

• Drilled and slotted rotors: These rotors combine both drilled holes and slots set in a spiral pattern around the outside of the rotor surface. They are used in high-performance vehicles, like sports cars.